Reusable mold forming tool

ABSTRACT

Embodiments of the disclosure provide methods, apparatus, and articles for making a plurality of molds described by CAD data in machine readable form using a reusable mold-forming device. Various embodiments include configuring a plurality of adjustable actuators fixed to a base of a mold-forming device, where the top surface of the adjustable actuators takes the form of the mold required to make the part described by the CAD data. The adjustable actuators may then be readjusted to form another mold surface.

FIELD

The present embodiments of the disclosure relates to the field of manufacturing molded parts, in particular, the method and apparatuses related to making molds.

BACKGROUND

In a manufacturing system environment, where small numbers of repeatable molded parts are required (e.g., aerospace industry, rapid prototyping), typically individual molds are machined from billets using Numerically Controlled (NC) methods from a Computer Aided-Design (CAD) model or surface, or a plaster splash from a machined male tool. Numerically Controlled (NC) machines continue to play an important role in the machining of metal tools having 3-D contoured shapes for production or prototype applications. Many organizations still machine high density foam to close tolerances to fabricate a form onto which composite tooling may be made; this is a labor-intensive method, but still a viable approach for deep drawn objects such as fighter radomes, or helicopter tailbooms. These methods are expensive due to each part requiring its own mold. Modifications and minor changes to molded parts are common as a design matures, requiring new molds. These modifications may be expensive as a new mold and splash are needed; typically, this slows the design and manufacturing process. The cost of storing individual molds for archiving tool changes and later use is expensive and time consuming. If manufacturing is occurring in different physical geographical locations there is also the added cost and time of transporting molds.

In the 1990s, rapid tooling became popular using methods like Selective Laser Sintering (SLS) and Stereolithography (SLA); although this method was faster and more cost effective than conventional machined or touch composite tooling, it could not be used for production due to its low temperature polymer composition, physical size limitations, high frangibility and poor ability to hold required tolerances.

Electron Beam Curing (EBC) was developed to speed the process of curing composites, but still relies heavily on traditional tooling. Currently, there are no disruptive tooling approaches for manufacturing advanced aerospace composite components, typically aerospace tooling costs approximately three times the production price of an aircraft, making it a large source of costs for the final product.

SUMMARY

Illustrative embodiments of the disclosure mold differently shaped parts using the same mold-forming device, which is adjustable and allows for modifications of the mold. This embodiment may comprise a plurality of adjustable actuators fixed perpendicular to a base, and arranged in a matrix, the ends of the adjustable actuators not fixed to the base being free to move in a direction perpendicular to the base.

The mold may be created by taking the CAD data of a part to be molded, using the CAD data to compute adjustments to the plurality of adjustable actuators into positions that represent the surface of a mold for the part to be formed. A repeatable flexible caul plate may then be placed on top of the adjustable actuators to form a mold surface. Once the adjustable actuators are in position they may be adjusted by the mold-forming device for thermal expansion, composite part spring-back, and thickness of the material to be formed using the mold. In this embodiment the adjustable actuators may have a feedback system allowing the adjustable actuators to be calibrated and their positions determined. The determined positions of the adjustable actuators may be corroborated against the input data allowing for quality control of the mold-forming device. Once the position of the adjustable actuators is verified with the input data the adjustable actuators may be locked into position. The embodiment may then have power withdrawn from the device and the actuators will hold their position, providing a stable tooling surface, and allowing the mold to be reused in the set position for more than one molded part. In various embodiments, the mold-forming device may be mobile and may be maneuvered into a curing device such as an autoclave. The mold-forming device may be constructed in a modular form so that a plurality of mold-forming devices may be joined together allowing for the possibility of manufacturing larger molded parts. Storage of molds is no longer required as the data to create the mold using the mold-forming device is all that is required to be stored. The data may be sent to distant geographical locations that are in possession of an embodiment of the mold-forming device, allowing manufacturing to take place quickly and cheaply wherever the devices are located. Rapid prototyping and modification is possible as the mold of molded part can quickly and easily be adjusted using the new data of the adjusted part, allowing for individual molded part comparisons to be carried out in their application environment.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings. Embodiments of the disclosure are illustrated by way of example and not by way of limitation in the figures of the accompanying drawings.

FIG. 1 depicts an embodiment of the mold-forming device used in various embodiments of the present disclosure.

FIG. 2 depicts a flowchart view of selected operations of the methods used in accordance with various embodiments of the present disclosure.

FIG. 3 depicts an exemplary architecture of selected computing components of the mold-forming device of FIG. 1 suitable for use to perform selected automated operations of FIG. 2, in accordance with various embodiments of the present disclosure.

FIG. 4 is a flow diagram of aircraft production and service method, in accordance with various embodiments of the present disclosure.

FIG. 5 is a block diagram of an aircraft, in accordance with various embodiments of the present disclosure.

DETAILED DESCRIPTION

Illustrative embodiments of the disclosure include, but are not limited to, methods, apparatuses, and articles of manufacture for a multiuse mold-forming device that may be electronically adjusted. Embodiments may contain a plurality of adjustable actuators fixed to a base, where the adjustable actuators are affixed perpendicular to the base. The adjustable actuators may be arranged in a matrix, where the adjustable actuator ends are opposite to the base end, are free to move, and are configurable. The mold-forming device may be mobile and contain a module capable of adjusting the adjustable actuators into a plurality of positions dependent upon input data coming from a CAD model or surface. The module adjusting the matrix arrangement of adjustable actuators may then allow the data from the CAD surface or solid model to position the adjustable actuator thereby configuring the top surface of the adjustable actuators to form the exact shape of the CAD surface to be tooled, this may be a male or female mold.

Various operations may be described as multiple discrete operations in turn, in a manner that may be helpful in understanding various embodiments; however, the order of description should not be construed to imply that these operations are order dependent.

The description may use perspective-based descriptions such as up/down, back/front, and top/bottom. Such descriptions are merely used to facilitate the discussion and are not intended to restrict the application of the embodiments.

The terms “coupled” and “connected,” along with their derivatives, may be used. It should be understood that these terms are not intended as synonyms for each other. Rather, in particular embodiments, “connected” may be used to indicate that two or more elements are in direct physical or electrical contact with each other. “Coupled” may mean that two or more elements are in direct physical or electrical contact. However “coupled” may also mean that two or more elements are not in direct contact with each other, but yet still cooperate or interact with each other.

For the purposes of the description, a phrase in the form “A/B” means A or B. For the purposes of the description, a phrase in the form “A and/or B” means “(A), (B), or (A and B).” For the purposes of the description, a phrase in the form “at least one of A, B, and C” means “(A), (B), (C), (A and B), (A and C), (B and C), or (A, B and C).” For the purposes of the description, a phrase in the form “(A) B” means “(B) or (AB),” that is, A is an optional element.

The description may use the phrases, “various embodiments” “in an embodiment,” or “in embodiments,” which may each refer to one or more of the same or different embodiments. Furthermore, the terms “comprising,” “including,” “having,” and the like, as used with respect to embodiments as described in the present disclosure, are synonymous.

FIG. 1 depicts an embodiment of the mold-forming device used in various embodiments of the disclosure. As illustrated, a mold-forming device may have a base 105, and the base may be a solid rectangular structure capable of supporting a matrix of electronic actuators; items for carrying out data processing, controlling devices for the adjustable actuators 103, a caul plate that may rest on the top surface 113 of the adjustable actuators 103, and any mold-forming material. The base may be set on casters 109 or a similar device allowing the mold-forming device to be maneuverable; allowing the device to be mobile within the manufacturing environment. This may allow the device to be maneuvered into a curing environment such as an autoclave. It may also allow the device to be maneuvered into a position allowing the mold-forming device to be locked together with other mold-forming devices. The mold-forming device may include a locking device (not shown) that couples the mold-forming device to other mold-forming devices, allowing a larger mold-forming device to be created from the smaller modular mold-forming devices. This larger mold-forming device made up of the embodiment allows for larger molded pieces to be created. The mold-forming device may also include an electronic interconnect module (not shown) allowing data to be transferred between the mold-forming devices when a plurality are joined to create a larger mold-forming device for creating larger molded parts. This may allow data to pass through the plurality of mold-forming devices so that the appropriate mold-forming device is configured, allowing the plurality of mold-forming devices to act as one large mold-forming device. The electronic interconnect module may allow data to be input into the mold-forming device from an external source, where the CAD model or surface data is stored or directly from a computer device that is capable of transferring mold data to the mold-forming device. The mold data may then be input into a module (not shown) that contains adjustable actuator logic and a storage medium for positions of the adjustable actuators 103, representing the CAD model or surface to be formed.

The base 105 of the mold-forming device may have a plurality of adjustable actuators 103 attached perpendicularly to the base 105 in the form of a matrix. The adjustable actuator base 111 may be fixed to the base 105 of the mold-forming device, the adjustable actuator 103 may be attached firmly holding the adjustable actuator perpendicular to the base 105 of the mold-forming device. In this embodiment, the adjustable actuators 103 are positioned as close together as possible to each other so that the top surface 113 of the adjustable actuators 103 may form a near contiguous surface.

CAD model data for a part or surface that may be molded by the device is input via the electronic interconnect module (not shown). The data may be computed using the module (not shown) into position data for the adjustable actuators 103. The computed adjustable actuator position data represents the position for each adjustable actuator 103 so that the plurality of adjustable actuators 103 may be configured into positions to represent a shape, or surface of a mold that will form the part described in the CAD model or surface data.

In this embodiment, to compute the positions for each adjustable actuator 103, the module that accepts the CAD model or surface data uses this data with one or more of the thermal expansion of the mold material, composite part spring-back of the mold, and thickness of the material to be formed using the mold.

Once the position data for each adjustable actuator 103 of the mold-forming device has been calculated, the module inputs the position data into the appropriate actuator driver which moves the adjustable actuator to the calculated position. Each adjustable actuator 103 is connected to an electronic feedback system (not shown) allowing the precise position of each adjustable actuator 103 to be determined, allowing the mold-forming device to verify the precise position of each of the adjustable actuators 103 for quality control. This may be accomplished automatically as the adjustable actuator's actual positions may be matched to the CAD model or surfaces computed positions, eliminating the need for Coordinate Measurement Mapping (CMM) or other tool inspection procedures. This feedback system allows quality control to be carried out automatically as each new CAD mold or surface data set is input into the mold-forming device, as the mold-forming device forms the mold.

In this embodiment, the adjustable actuators 103 are locked into position once the position of each adjustable actuator is verified with the CAD model or surface. The locked actuator allows the mold-forming device to be detached from any power source and the electronic interconnect module (not shown). The locked adjustable actuators may now hold their positions which form the shape of the mold representing the part described by the CAD model or surface. A repeatable flexible caul plate 115 may now be laid on the top surface 113 of the automatic actuators. This may be a highly ductile material that is flexible in all directions, e.g., a Teflon plate, thin aluminum, or high temperature rubber.

The mold-forming device may now have the mold-forming material laid on top of the caul plate and the mold-forming device maneuvered into a curing environment for the particular mold-forming material being used. The mold-forming device may be used to make copies of this part as necessary. The mold-forming device may hold its shape as the adjustable actuators 103 are locked into position. When a new mold shape is required the mold-forming device is reattached using the electronic interconnect module (not shown) to a device holding the CAD model or surface of the new shape. The process may be repeated for the new mold shape. If the original shape is required at some time in the future, the data can be re-input into the mold-forming device so the device can again reposition the adjustable actuator into the original positions allowing the original shape to be formed.

FIG. 2 depicts a flowchart view of selected operations of the methods used in accordance with various embodiments of the disclosure. In this embodiment, the mold-forming device may receive the data that represents the mold-form as CAD data of the model or surface, block 201, to be shaped. In other embodiments the data may be in the form of electronic data representing the shape to be formed by the mold-forming device.

If more than one mold-forming device is required, block 210, to form the mold, one or more mold-forming devices as required, may be connected together. The mold-forming devices may have physical connectors that allow the mold-forming device to be locked together, block 202. This locking together may physically attach one mold-forming device to another mold-forming device, where a process to detach them may be required to separate the mold-forming devices from one another. This may allow the mold-forming devices to revert back to their singular state. Once locked together the one or more mold-forming devices form a larger mold-forming device required to mold a larger part, this may be because the mold to be formed is too large to be formed on one mold-forming device.

The CAD data of the mold, block 201, may be input into the mold-forming device through the electronic interconnect module, the data being input into a module containing computational logic 314 (shown in FIG. 3). The module generates data for the positions of the adjustable actuators, block 203, using computational logic 314 (shown in FIG. 3) and actuator logic 316 (shown in FIG. 3). Once the position for each adjustable actuator 103 (shown in FIG. 1) has been calculated, further refinement of the adjustable actuator 103 (shown in FIG. 1) position may take place. In this embodiment the position of the adjustable actuator 103 (shown in FIG. 1) may be refined by further generating data for the position of the adjustable actuators 103 (shown in FIG. 1) based upon a thermal expansion, block 204. This embodiment may include the position of the adjustable actuator 103 (shown in FIG. 1) being refined by further generating data for the position of the adjustable actuator 103 (shown in FIG. 1) based upon a composite part spring-back, block 206. This embodiment may further refine the position of the adjustable actuator 103 (shown in FIG. 1) by further generating data for the position of the adjustable actuator 103 (shown in FIG. 1) based upon a thickness of the material to be formed, block 208.

The position data for each adjustable actuator 103 (shown in FIG. 1) may then be used to configure each adjustable actuator via the data communication interconnect, block 205, using the actuator driver 320 (shown in FIG. 3), contained in the module of the mold-forming device. The data communication interconnect socket may allow data to be transferred from an outside source; this may be another computer device from which the data is input into the mold-forming device. Once the adjustable actuators have been configured, the adjustable actuators may be locked, block 207. An electronic feedback system may provide feedback of positions of adjustable actuators, block 209, to allow the precise position of each adjustable actuator to be determined for quality control purposes. Once the precise position of the adjustable actuators has been provided, the mold-forming device verifies the position of the adjustable actuator, block 211, with the CAD model data that was provided to determine the positions of the adjustable actuators. If an adjustable actuator is found to be in the wrong position, the mold-forming device configures the adjustable actuator, block 205, again. This process is repeated until the positions of all of the adjustable actuators can be verified with the input CAD model data.

In this embodiment of the disclosure, once the position of the adjustable actuators 103 (shown in FIG. 1) has been verified, block 211, removal of power from the mold-forming device, block 212, may be performed. The adjustable actuators 103 (shown in FIG. 1) are locked into their verified position and with the removal of power from the mold-forming device remain in the same position. The mold-forming device may be used one or more times without being reconnected to a power source, the locked adjustable actuator 103 (shown in FIG. 1), locked into the position determined by the CAD input data.

Once each of the adjustable actuator's positions has been verified, a flexible caul plate 115 (shown in FIG. 1) may be disposed upon the upper surface of the actuators, block 213, with the caul plate in place the mold material may be applied to the mold, block 215. The mold-forming device can now be moved to an environment to cure the mold and then ready the mold-forming device for another mold, block 217. If the same part is required, the mold-forming device may be reused as the adjustable actuators are locked into position. If a new mold part is required, the operations are repeated, the mold-forming a new shape dependent upon the input data.

FIG. 3 depicts an exemplary architecture of selected computing components of the mold-forming device suitable for performing the described operations of various embodiments of the present disclosure. As shown, computing components 300 may include one or more processors 302 and memory 304. Additionally, computing system/device 300 may include mass storage devices 306 (such as diskette, hard drive, CD-ROM and so forth), and communication interfaces 310 (such as network interface cards, modems and so forth). The elements may be coupled to each other via system bus 312, which represents one or more buses. In the case of multiple buses, they may be bridged by one or more bus bridges (not shown).

Mass storage 306 and memory 304 may be employed to store a working copy and a permanent copy of the programming instructions implementing one or more aspects of the above described teachings to practice the mold-forming device methods and apparatuses of the present disclosure, such as computational logic 314. The programming instructions may be implemented in assembler instructions supported by processor(s) 302 or high level languages, such as C, that may be compiled into such instructions.

The permanent copy of the programming instructions may be placed into mass storage 306 in the factory, or in the field, through, e.g., a distribution medium (not shown) or through communication interface 310 (from a distribution server (not shown)).

Mass storage 306 may contain actuator logic 316 and storage for position data 318 for each adjustable actuator. The actuator logic may be the logic required to convert surface or model data into actuator position data, computing where each individual adjustable actuator from the plurality of adjustable actuators arranged in a matrix should be positioned to represent the surface or model of the CAD data to be molded. Once each adjustable actuator position is calculated the position data may be stored in the position data storage 318. The adjustment of the adjustable actuators may require an actuator driver 320, each adjustable actuator may have its own instance of the actuator driver, the position data for each adjustable actuator stored in the position data 318 may be communicated to the actuator driver 320 via the bus 312. The actuator drivers 320 may then adjust the adjustable actuators to the computed position, allowing the plurality of adjustable actuators to form a surface with the end of adjustable actuators, the end being opposite to the end fixed to the base.

Referring more particularly to the drawings, embodiments of the disclosure may be described in the context of an aircraft manufacturing and service method 400 as shown in FIG. 4 and an aircraft 502 as shown in FIG. 5. During preproduction, exemplary method 400 may include specification and design 404 of the aircraft 502 and material procurement 406. During production, component and subassembly manufacturing 408 and system integration 410 of the aircraft 502 takes place. Thereafter, the aircraft 502 may go through certification and delivery 412 in order to be placed in service 414. While in service by a customer, the aircraft 502 is scheduled for routine maintenance and service 416 (which may include modification, reconfiguration, refurbishment, and so on).

Each of the processes of method 400 may be performed or carried out by a system integrator, a third party, and/or an operator (e.g., a customer), as indicated by the “X” in the grid to the right of the flow diagram of FIG. 4. For the purposes of this description, a system integrator may include without limitation any number of aircraft manufacturers and major-system subcontractors; a third party may include without limitation any number of venders, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, and so on.

As shown in FIG. 5, the aircraft 502 produced by exemplary method 400 may include an airframe 518 with a plurality of systems 520 and an interior 522. Examples of high-level systems 520 include one or more of a propulsion system 524, an electrical system 526, a hydraulic system 528, and an environmental system 530.

Apparatus and methods embodied herein may be employed during any one or more of the stages of the production and service method 400. For example, components or subassemblies corresponding to production process 408 may be fabricated or manufactured in a manner similar to components or subassemblies produced while the aircraft 502 is in service. Also, one or more apparatus embodiments, method embodiments, or a combination thereof may be utilized during the production stages 408 and 410, for example, by substantially expediting assembly of or reducing the cost of an aircraft 402. Similarly, one or more of apparatus embodiments, method embodiments, or a combination thereof may be utilized while the aircraft 502 is in service, for example and without limitation, to maintenance and service 416.

Although specific embodiments have been illustrated and described herein for purposes of description of the preferred embodiment, it will be appreciated by those of ordinary skill in the art that a wide variety of alternate and/or equivalent implementations may be substituted for the specific embodiment shown and described without departing from the scope of the disclosure. Those with skill in the art will readily appreciate that the present disclosure may be implemented in a very wide variety of embodiments. This application is intended to cover any adaptations or variations of the embodiments discussed herein. Therefore, it is manifestly intended that this disclosure be limited only by the claims and the equivalents thereof. 

1. A method for making a plurality of molds, comprising: configuring a plurality of adjustable actuators of a mold-forming device to a first plurality of positions for forming a first mold, using first CAD data of the first mold; forming the first mold using the mold-forming device; reconfiguring the plurality of adjustable actuators of the mold-forming device to a second plurality of positions for forming a second mold, that is separate and distinct from the first mold, using second CAD data of the second mold; and forming the second mold using the mold-forming device.
 2. The method of claim 1, further comprising generating the data for positioning the plurality of adjustable actuators of the mold-forming device, the data describing a mold form.
 3. The method of claim 1, further comprising locking the plurality of adjustable actuators in specified positions.
 4. The method of claim 3, wherein the locking further comprises continuing locking the plurality of adjustable actuators in specified positions while the mold-forming device receives no power.
 5. The method of claim 1, further comprising receiving electronic feedback from the at least one of the adjustable actuators, wherein the plurality of adjustable actuators include an electronic feedback system attached to each actuator, providing verification feedback of the current positions of the adjustable actuators.
 6. The method of claim 5, wherein the verification feedback of the adjustable actuators is compared to input CAD data for the mold being formed.
 7. The method of claim 1, further comprising locating the mold-forming device on a mobile platform.
 8. The method of claim 7, wherein the mold-forming device on the mobile platform further comprises physical connectors allowing a plurality of mobile platforms to be joined.
 9. The method of claim 1, wherein the configuring further comprises computing positions of each of the plurality of adjustable actuators based upon a thermal expansion.
 10. The method of claim 1, wherein the configuring further comprises computing positions of each of the plurality of automatic adjustable actuators based upon a composite part spring-back.
 11. The method of claim 1, wherein the configuring further comprises computing positions of each of the plurality of adjustable actuators, based upon a thickness of the material to be formed into a mold.
 12. The method of claim 1, further comprising disposing a flexible caul plate upon the upper surface of the plurality of adjustable actuators.
 13. The method of claim 1, further comprising providing an interconnect socket allowing the mold-forming device be coupled with a plurality of mold-forming devices, allowing data communications to transfer through the interconnect socket.
 14. The method of claim 1, further comprising providing a data communication interconnect socket to the mold-forming device for receiving data at the mold-forming device.
 15. An apparatus for forming a mold comprising: a plurality of adjustable actuators each including an upper surface adapted to receive a material to be formed into a mold; a base unit supporting the plurality of actuators; and a module operatively coupled to the plurality of adjustable actuators and adapted to: configure the plurality of adjustable actuators to a first plurality of positions for forming a first mold, using first CAD data of the first mold, facilitate forming the first mold, reconfigure the plurality of adjustable actuators to a second plurality of positions for forming a second mold, that is separate and distinct from the first mold, using second CAD data of the second mold; and facilitate forming the second mold.
 16. The apparatus of claim 15, wherein the module is further adapted to generate the data for positioning the plurality of adjustable actuators, the data describing a mold form.
 17. The apparatus of claim 15, wherein the module is further adapted to lock the plurality of adjustable actuators in specified positions.
 18. The apparatus of claim 15, wherein the module is further adapted to lock the plurality of adjustable actuators in specified positions while the mold-forming device receives no power.
 19. The apparatus of claim 15, wherein the base unit is further located on a mobile platform.
 20. The apparatus of claim 19, wherein the mobile platform further comprises physical connectors allowing a plurality of mobile platforms to be joined.
 21. The apparatus of claim 15, wherein the module further comprises an interconnect socket allowing coupling with a plurality of modules, allowing data communications to transfer through the interconnect socket.
 22. An article of manufacture comprising: a storage medium; and a plurality of programming instructions stored on the storage medium and configured to program a mold-forming device to configure a plurality of adjustable actuators of a mold-forming device to a first plurality of positions to form a first mold, using first CAD data of the first mold; form the first mold using the mold-forming device; reconfigure the plurality of adjustable actuators of the mold-forming device to a second plurality of positions to form a second mold, that is separate and distinct from the first mold, using second CAD data of the second mold; and form the second mold using the mold-forming device. 